6-Cylinder Engine
Electric A/C Compressor Removing from Bracket
With high voltage systems (hybrid vehicles)
Read and follow all of the supplemental warnings for all work performed on vehicles with the high voltage system.
Risk of unintended engine start
The ignition must be turned off and the ignition key must remain outside of the vehicle when working on vehicles with a high voltage system.
How to handle high voltage cable:
• Do not stand on or place tools on high voltage cables and their components as it may damage the cable insulation.
• Never bend or kink high voltage cables forcefully as it may damage the cable insulation.
• Color-code the round high voltage connector with an external color ring and code them mechanically using the guide- or code tabs. Always make certain that the coding matches when connecting the round connector in order to avoid mechanically damaging the high voltage connector.
There is a risk of electrocution from damaged high voltage components
Observe the following when working around high voltage components and high voltage wires:
• Never work around high voltage components and cables with cutting, deformed, or sharp edged tools, or heat sources such as welding or soldering tools, heated air, and thermal glue.
• Inspect the high voltage components visually before beginning.
• Perform a visual inspection of the electric drive power and control electronics (JX1) , the electro-drive drive motor (V141) , the A/C compressor (V470) and the high voltage lines when working in the engine compartment.
• Perform a visual inspection of the high voltage lines and the cover when working on the underbody.
• Perform a visual inspection of the high voltage lines and the Electrobox with the high voltage system maintenance connector (TW) when working in the luggage compartment.
• Perform a visual inspection on all of the potential equalization cables.
Observe the following items when performing the visual inspection:
• The components do not display any signs of external damage.
• The high voltage cable insulation and the potential equalization cables are not damaged.
• The high voltage cables do not display any abnormal deformations.
• Every high voltage component is marked with a red warning label.
• With A/C compressor control module (J842) and electric A/C compressor (V470)
• The electric motor for the A/C compressor is powered with voltage from the electric drive power and control electronics system (JX1).
• The A/C compressor control module, integrated in the A/C compressor, controls the rotation and thereby the output of the A/C compressor corresponding with the Data bus receiving requirements. Refer to the Vehicle diagnostic tester in "Guided Fault Finding" Function for the A/C System and the Battery Control.
• There is no A/C compressor regulator valve (N280) installed in the electric A/C compressor, the output of the A/C compressor is regulated via the exterior rotation of the A/C compressor. Refer to and the Vehicle diagnostic tester in "Guided Fault Finding" Function for the A/C System and the Battery Control.
• The electric A/C compressor functions according to the principle of a spiral charger (similar to a G-charger).
• The A/C compressor control module (J842) and the electric A/C compressor (V470) are components and are currently not able to be separated.
The following procedure requires working on the high voltage system. De-energize the high voltage system.
• You can remove and re-install the A/C compressor in vehicles with 4 cylinder engines. The compressor can be removed and installed at the bracket without opening the refrigerant lines.
• Do not discharge the refrigerant circuit to remove the bracket, do not remove refrigerant hoses and lines from A/C compressor.
• Do not unfasten refrigerant pipes and corresponding clamps.
• The cable for the high voltage system remains connected to the A/C compressor. Do not release the electrical connection for the high voltage system from the A/C compressor.
• After removing the A/C compressor, tie it to the vehicle with wire. Do not let it hang by the refrigerant lines.
• Different A/C compressors may be installed depending on engine and country variant. Refer to Electronic Parts Catalog (ETKA).
Removing
The following procedure requires working on the high voltage system. De-energize the high voltage system.
- Turn off the ignition.
- De-energize the high voltage system.
Disable the high voltage system
Risk of electrocution
Death or serious bodily injury by electric shock.
• People with electric/medical life- and health sustaining devices in or on their person must not perform any work on the high voltage system for safety reasons. Internal pain killer pumps, implanted defibrillators, pacemakers, insulin pumps and hearing aids among others are considered life- and health sustaining devices.
• The high voltage system may only be activated by qualified personnel (Audi high voltage mechanic).
• Make sure that the high voltage system is completely de-energized using the Vehicle diagnostic tester in "Guided Fault Finding".
• The qualified person (Audi high voltage technician) determines the voltage and secures the system from restarting using the locking cap (T40262). Keep the ignition key and the high voltage system maintenance connector (TW) safely with the qualified person to secure the system from restarting.
• The Audi high voltage technician should put a sign on the vehicle to identify it as a high voltage vehicle.
• Disable the high voltage system:
• Connect the vehicle diagnosis tester
• Select the Guided Fault Finding mode
• Using the GO TO button, select the following menu commands
• Functions/Component selection
• Body
• Electrical Equipment
• OBD-capable system
• 8C - Hybrid battery management -J840
• 8C - Hybrid battery management, functions
• 51 - Disable the high voltage system (Rep.Gr. 93)
- Remove the engine cover.
- Loosen the clamps - arrows - and remove the air guide hose.
• Ignore - 1 -.
- Free up the high voltage system connector - 3 - on the engine.
- Disconnect the connector - 2 - (for low voltage on the A/C compressor).
• Ignore - 1 and 4 -.
- Remove the bolts - arrows - from the A/C compressor.
- Remove the A/C compressor - A - and move it as far as possible away from the engine on the left side in such a way that the cable for the high voltage system - C - or the coolant hose are not kinked or bent.
There is a risk of damaging the cable or the connector for the high voltage system
• Do not bend or twist the connector for the high voltage system - B -.
• Do not twist, stretch, kink, or bend the cable for the high voltage system - C -.
- Secure the A/C compressor to the vehicle (for example, with a wire) without pulling or bending the high voltage system cable or the coolant hoses.
There is a risk of damaging the high voltage system cable or the refrigerant lines and hoses.
• Do not stretch, kink or bend refrigerant lines and hoses.
• If the A/C compressor cannot be swiveled away enough from the engine, then the A/C compressor must be removed. Refer to => [ Electric A/C Compressor ] Electric A/C Compressor.
Installing
Installation is done is reverse order, observe the following:
• Check the bolting points of the A/C compressor and the bracket prior to installation. The contact surfaces must be clean and rust and grease-free. Otherwise, repair the contact surfaces with the contact surface cleaning set (VAS 6410).
Only activate the electric A/C compressor when the refrigerant circuits is filled. The A/C compressor may become damaged if the A/C compressor is run while the refrigerant circuit is empty. Refer to the Vehicle Diagnostic Tester in "Guided Fault Finding" Function for A/C System and Battery Regulator.
• After the installation of the electric A/C compressor and the subsequent filling of the refrigerant circuit, start up the A/C compressor for the first time using the "compressor intake" function for the basic setting. The A/C compressor may otherwise become damaged if before installation, refrigerant oil was improperly stored in the A/C compressor compression chamber, refer to => [ Electric A/C Compressor Overview ] Electric A/C Compressor Overview and the Vehicle Diagnostic Tester in "Guided Fault Finding" Function for A/C System and Battery Regulator.
- Tighten the bolts - arrows - (tightening specification: 25 Nm).
- Connect the connector to the electric system.
• After fastening the A/C compressor, check installation position of refrigerant lines, lines must be engaged in bracket (if installed, depending on engine).
• Check refrigerant lines and their bracket to ensure there is enough distance to the other components. Ensure there is also enough distance between belts, bracket and pulley.
- Secure the electric high voltage system cable to the designated engine points.
- Secure the clip - 1 - to the engine - 2 - and cable holder - 3 - on the wiring harness - 4 - as illustrated.
- Install the air guide hoses with screw-type clamps.
- Install the remaining removed components.
- Energize the voltage to the high voltage system.
Restart the high voltage system
Risk of electrocution
Death or serious bodily injury by electric shock
• People with electric/medical life- and health sustaining devices in or on their person must not perform any work on the high voltage system for safety reasons. Internal pain killer pumps, implanted defibrillators, pacemakers, insulin pumps and hearing aids among others are considered life- and health sustaining devices.
• The high voltage system may only be restarted by qualified personal (Audi high voltage technicians).
• Assure that the restart is performed exclusively using the Vehicle Diagnosis Tester according to the "Guided Fault Finding".
• The qualified person (Audi high voltage technician) restarts the vehicle.
• The qualified person (Audi high voltage technicians) marks the vehicle by attaching warning labels.
• Restart the high voltage system:
• Connect the vehicle diagnosis tester
• Select the Guided Fault Finding mode
• Using the GO TO button, select the following menu commands
• Functions/Component selection
• Body
• Electrical Equipment
• OBD-capable system
• 8C - Hybrid battery management -J840
• 8C - Hybrid battery management, functions
• 51 - High voltage restart (Rep.Gr. 93)
- Switch on the ignition.
- Check and, if necessary, erase the displayed faults in the DTC memory for the Climatronic control module (J255) and the A/C compressor control module (J842). Refer to the Vehicle diagnostic tester in "Guided Fault Finding".